Means for positioning core bars in horizontal pipe casting apparatus



MEANSfFO'R P'OSITIONING CORE BARS IN HORIZONTAL PIPE CASTING APPARATUS FiledvJune', 1943 2 Sheets-Sheet l Nov. 14, 1944. J E. csoATEsy 2,362,899

- Nov. 1.4, 1944.

' J. E. GOATEs. 2,362,899

MEANS FOR POSITIONING'CORE BARS IN HORIZONTAL PIPE CASTING APPARATUS Filed June 5, 1943 -2 sheets-sheet 2O y l www/vg:

Patented Nov. 14, 1944 www UMT'ED 'STATES PATENT OFFICE MEANS FOR PosIiTIoNING CORE BARS IN HomzoN'rAL PIPE CASTING APPARATUS John Elijah cuates, Previo, Utah, assignor to Pacific States Cast Iron Pipe C0., Provo, Utah,

a corporation of Nevada y Applicaton'June 5, 1943, Serial No. 189,822

17.2 Claims.

The invention relates generally yto the art of Several conditions may be encountered which will casting pipe in a horizontal position and primarily seeks to provide novel means for placing the cores in the flasks so that they will bev perfectly centered Within the molding surfaces at the time the castings set by the solidification of the molten metal, thereby to assure perfect uniformity `inthickness ofthe cast Wall structuresand avoid the Wastage of Imetal heretofore experienced because of the prior necessity of providing suiiicient toler' tered* with'respect to the mold cavity, and these chaplets, being cast into the pipe or other article,

resulted in the formation of leakage spaces bejtween the stemsof the chaplets and the metal cast around the stems. Chaplets were employed in order to prevent deflection of the core or core bar d-ue to several different forces, viz.; `the Weightl of the core or core bar, the substantiallyvlateral pressure on the core exerted by the velocity pressure of the stream of lmetal entering the mold, the unequal expansion of the top `and bottom portions of the core bar resulting from the bottom of the bar bein-g heated rbefore the` top thereof during filling ofthe moldfrom the bottom upland the upward vertical force due to the natural buoyancy of the core in the molten metal. y

Prior to the presentinvention apparatus has been devised for initially fixingI the positions of the cores in the flasks so that atthe midpoint in the length of each core the core bears an eccentric relation within the molding surfaces, thev degree of eccentricity being estimated in. lan amount Aequal to and in directions opposite from thefanticipated movementof the core upwardly and laterally under the influence of the poured molten metal.` An example of a prior art disclosure of such apparatusais to be found in U. S. Letters Patent 2,042,907issued to James R. McWane on l June 2,1936.l Such improved casting apparatus has beenv very beneficial and'has brought about markedadvances rin the art but also has been limited inl efficiency in attaining the desired endV of providing cast pipe having uniform Wall thickness throughout andfvvhieh is cast with a minimum of Waste, For example, the actual moveyments of the cores fwhen the-mold istpoured-is seldom exactly equal to the anticipated l movements for which the cores have been initiallyset.

bringabout movement of one or more cores from their initial setting such as Will result in the casting of pipe with non-uniform Wall thicknesses.

l For instance, after the cores are set in the drag v of the flask in the initial position expected ultimately toresult in placement in perfect centered relation in the flask, placing ofthe cope on the drag very often causes one or more-of` the cores to move as much as y.05, and clamping the flask. drag and cope together and the transferring of the flask to the pouring floor also often causes the cores to move out of their initially set positions. Prior to the present time no practicalmeans has been devised to detect and measure this movement of cores from their initially set positions. l It is therefore an object of the present inventionto provide novel means for detecting and measuring movement of the cores from their initially set positions, and said invention comprehends not only the provision of this novel core-bar movement measuring means but also` the combination thereof with means for adjusting the positions of the core bars so that When movement of core bars out of their initially set positions is detected, ,the adjusting means and the measuring means can vbe used in combination to effectadjustment of core bars duringand immediately after pouring of the f molten metal, thereby to assure attainment ofthe desired perfectly centeredy relation of the` cores Within the molding surfaces in the flask just priorr to solidication of the molten metal.

In its more 'detailed nature the invention re sitioned by'saidcontact, and of .alength for projecting a considerable distance beyond one end of said core bar, said extended vend resting upon a fulcrum inwardly of its extended end extremity,

and gaugemeans being providedandengaged by said lever adjacent its eXtendedend extremityfor indicating the degree of displacement of the op-v posite end of the lever by reason of its contact in the core bar and `as a result of deflection of the core bar from its initial setting in the flask.

Another object of the invention is to provide in a gauge equipment of the character Stated a novel mounting for agauge set comprising two gauge units each equipped with' a lever end co-ntacting spring plunger, one said unit being. placed for actuation by movement of the lever end laterally and the other being placed for actuation by movement of the lever end vertically. I

Another lobject of the invention is to provide agauge equipment of rthe character statedl in combination with means on the ask for suptherein and which include threadably mounted devices adjustable to engage and bend the cores to providethe desired amount of deflection therein in the initial setting of the cores in the ilask and also for readjusting the initially set deflection in said cores should the gauge equipment reveal that the initially set core deection has been disturbed by closing or moving of the flask, or has been improperly selected and must be altered following the pouring of the mold and before the molten metal solidiiies in order to provide for the necessary perfect centering of the cores in the iinishedcasting.

With the above and other objects in view that will hereinafter appear, the nature of the invention will be more fully understood by following the detailed' description, the appended claims and' the several views illustrated in the accompanying drawings.

In the drawings:

Figure 1 is a plan view illustrating the invention, parts being broken away` and the cope of ther ask being removed'.

Figure 2 is a side elevation illustrating the apparatus shown i-n Figure l.

Figure 3 is a left end elevation on the apparatus illustrated in` Figure 1.

Figure 4 is an enlarged fragmentary vertical cross section illustrating the contact ofa gaugeV lever in one of the hollow cores intermediate the ends thereof.

Various forms of casting ask structure may be employed in practicing the invention and in the example of embodiment of the invention herein disclosed the flask structure includes a drag 5r and a cope 6. Each drag andI cope includes spaced endwalls l and 8- having clearances 9 therein in which to receive-the multiple of hollow core bars generally designated Illy which are arranged side by side in the flask in the manner clearly illustrated inv Figures l and 3 of the drawings.

Each core bar includes. a 4bell end II and a spigot end I2, and' when positioned in the flask in the manner illustratedv in Figure l the core sand on the cores and the molding sand in the flask cavities cooperateV to provide between them suitable cavities I3 in which the pipes are cast, each said pipe being formed with a bel-l portion I4 at one end and a spigot portion I5 at its other end'. Each cope and drag also is provided witha central end projection IS at each end for receiving crane tackle in a manner for facilitating handling of these heavy casting apparatusA units. The cope and dragsectlons 5 and 6 are clampedA together 'in superposed relation by the usual clamps lil in the manner clearly illustrated in Figures 2 and 33,. and during the actual pouring of the mold the flask structure may rest firmly on endl supports generally designated I8". SuitableY antiiri'ction roller equipments I9 arey provided intermediately' ofthe end supports I8 and' facilitate movement of the ilask structure into position at the pouring station.

Each drag section 5 is provided with longitudina'lly spaced sets of side lugs 20 and 2l at each end thereof in position for receiving the respective bell and spigot ends I I and I2 between the lugs 20' of each set. Adjuster screws 22l are threaded through the lugs 2n and 2I so as to engage inwardly against the sides of the respective core bellv and spigot ends II and I2 in the `marmer clearly illustrated in Figure l.

A single endwi-se extending lug 23 is provided at Cil each end of the drag section 5 in position for extending beneath the respective ends of each core .bar I 0, and a single adjuster screw 24 is directed upwardly through eachlug 23 in position for engaging upwardly'against the overlying core bar end. A yoke 25 is removably mounted over each core bar end the associated, longitudinally spaced sets of adjuster screw lugs 2|)v and 2l in the manner clearly illustrated' in Figure l, the arms of each yoke being anchored against upward movement as at 26"., The yokes serve the purpose of resisting upward movement of the core bars from their adjustable supports or mountings comprising the underlying adjuster screws 24 and the horizontally inwardly directed adjuster screws 22, and each yoke is equipped with a downwardly directed adjuster screw 2"!" which engages. the. upper surface of the respective end of the associated corebar.

It will be obvious from the foregoing that by a proper adjustment of the vertically' directed' adjuster screws 241 and 21 the individual core bars can be bent or deflected upwardly or downwardly at the central portions thereon, or intermediate their ends, and by properly adjusting the horizontally inwardly directed adjuster screws 22 bending of the corev bars in the horizontal direction can be accomplished in similar manner.

The structure described hereinabove is well known in the art and an example of' this type of equipment is disclosed in U. S. Letters Patent 2,042,907v issued to J. R. McWane on June 2, 1936, andsuch apparatus forms no part of the present invention except in combination with the core bar deflection detecting and indicating equipment soon to be described. By utilizing the adjustable core supporting and positioning equipments hereinbefore described by properly adjusting the devices 22, 24' and 28 included therein, the core bars can be bent or deflected in the initial assembling of the ask or mold' so as to place the central or intermediate portions of the core bars eccentrically in theV ask structure in anticipation of the known effect of the inpouring molten metal to lift the central portions of the core bars and also to laterally deflect said portions. By thus initially setting the central portions of the core bars below the axis of the mold by an amount equall to the anticipated rise of the core when the mold is poured, and also to one side toward the linpouring molten metal by an amount equal to the anticipated lateral deflection of the core when the mold is poured, it is possible to approximate a perfect centering of the core bars in the metal ofthe cast as it solidies in the molding cavities. It is the purpose of the present invention to provide a gauging equipment by which it is possibleto accurately determine the degree of deflection of the core bars, and also to accurately determine the amount of deflection actually caused by the inrushing molten metal during the pouring of the mold so that the core bending devices hereinabove referred to can be employed while the pouring of the mold is in progress and before the molten metal solidies so as to absolutely assure perfect centering of the core bars in the fini-shed castings and the provision of' casting walls of uniform thicknesses throughout without the necessity of providing tolerances which would result in the use of an unnecessarily large amount of metal in order to provide the desired strength in the finished pipe throughout the length thereof. The improved gauging equipment includes frame uprights 28 which serve as a support for a transversely disposed pouring platform P which may I0 or II intermediately of serve as a support'foran operative in` chargeof the mold pouring activities.- The uprights 28 .also serve as supports` for ahorizontallyV and transversely disposed-shelffS vfrom the inner edge of which upwardly projectsaknife edge fulcrum l,

bar 29 which preferably extends across 'the full i Width of the flask structureA so as-to beoommon to'all of the multiple of coresl mounted. therein.

'I'he uprights 28 alsosupport an uprightly positioned channel beam 30 which' is disposedabove and to one side of and parallelthe shelf Si? The beam'30'serves asa support forV a 'plurality'of brackets 3|, one such bracket -being provided for cooperatingwith anl individual gauge equipment associated with each core 'ban Each bracket includes an inverted AU-shapedportion .32y which -f V leg 36 on which a standard Starret` gauge 31 is tiltablymounted as at 38. The gauge' 31 includes a spring projected actuated plunger 39. Each bracket also includes a lateral .depending leg 40 including ahorizontal foot portion 4l on which a down, "and14V the otherv gauge unit 42Will indicate lateral movement of the lever endin either direction. `Any movement of the lever end other than strictly vertical or lateral willindicate a certain amount on both gauges. 'The gauges used are the cbmmon dial ty'pe employing an indicating hand actuated" by a spring projected plunger. The

second standardfStarret gauge 42 ris tiltably mounted as`at'43, the gauge units 31 and ily together forming a gauge Set. Each gauge 42 also spring'fvvhich projectseach plunger acts against the 'plunger' so that vif unrestrained the plunger will move to its outer limited position. Each actuator plunger is held against the associated lever end bythe plunger projecting spring and any movement of the plunger in or out will result in the provision of a deflection indication on the respective gaugedial.I y

-Before closing the flask or mold, the cores are setto the predetermined vpositionsin the usual manner as hereinbefore described, the central portion of each core being bent to an eccentric position in ,theA molding cavity, slightly below the axis of the'cavityfin anticipation of the lifting effect Aof the inrushing molten metal, and to one vside o f said axis toward the'direction of the pour v in anticipation of the lateral deflection resulting [from the inpouring of the `molten metal. After the flask has been closed and moved to the pouring station the deflection gauging equipments can be mounted in the manner illustrated in Figures l, 2 and 3 of the drawings in order to detect and indicate core bar deection during the pouring of the mold. During the pouring of the mold, movement of the outer ends of the levers 45 will act on the gauge units 31 and 42 of the respective Y sets in a manner for indicating any movement of includes a spring projected actuator plunger 44.

A rigid gauge lever 45 is associated With each core bar and is extended in the manner illustrated in Figures 1 and 2 of the'drawings through the adjacent open endvof the respective core bar into position for, having the spider 46 which is welded `or, otherwise secured to the inner end thereof engage-With the internal wall `off'said core kbarnear the central portion thereof, that is, intermediate the ends ofy the core bar v` The spider 46 may benshapedin any approved manner and in thepresent disclosure takes the form of a simple inverted VU piece disposed to have the extremities of the `U legs engage the central portion of the core bar so that any movement of the central portion yof the core barwill'be irnparted to the engaging gauge lever end and be v transmitted to the outer end portion of said lever WhichfeXtends-from theopenend of the respecv tivecore bar. K y A, A The" outer ends of the levers 45 which project beyond the open ends vof the core .bars ,extend over and rest upon" the common fulcrum bar 2S),y

and the end extremities of l'said levers beyond the fulcrum bar extend 4between and engage the actuator plungers' 39 and M of the' respective gauge unit sets in the manner clearly illustrated in Figure 3 ofthe drawings. Each lever may havek an inverted U piece 41 Welded or "otherwise,

securedv thereto at'the position of thelassociated gauge units 31 and 4,2, the Yflat top ofthe Uppiece serving as a flat surface .with which the vertically and downwardly directed plungerl 39 can engage, and one upright .legfof the: U piece serving as a flat surface against whichfthefl'iorizontallyl di-v rected actuator plungered'projects'; With vthe parts relatedin the manner described "and clearly illustrated in Figure 3, one gauge unit 31 will serve to detect and indicate `any movement pf ,Y the lever end in afvertical direction, either `up or the deflection ofthe central portions of the cores, since any radial movement of the ends of the levers maybe resolved into vertical and horizontal`- components, the gauges will indicate defiection'in any direction. The movement of the gauge actuating end extremities of the levers being in exact proportion to the movement of the lever ends which extend into the core bars, depending on relativelever arm lengths, the gauges maybe calibrated to indicate the `exact amount of radial movement of each core bar at its mid point. Y

Ify the micrometer gauges show that the actual rise of a given core is more or less than the anticipated amount', the particular adjusterscrew equipments 24 and 21 can be utilized to quickly adjust the core tothe correctly centered position inthe molding cavities before solidication of the metal in the molding cavity takes place. Similarly, any vlateral radial adjustment of the core bars under vlike conditions can be effected by manipulation of the adjuster screws 22. Long handley ratchet wrenches 48 having reversible heads o r sockets 49 can be utilized for turning the screw equipments in one ldirection or the rother in effecting the desired bending adjustment of thecorebars. e'

`.If desired, a suitable heat insulator jacket 5B can be providedon each lever 45 throughout the lengthfo'f that portion thereof which is intended to lie within core bars and an additional portion vthereof extending withoutthe core bars so as to protect the lever from the effects of excessive heat within ythe cores.

By closely controlling the Wall thicknesses of the cast pipe by use ofthe improved apparatus herein disclosed a considerable saving of metal Willjresult because it is not necessary to make as nesses as has' been necessary heretofore, and

greater uniformity in wall thickness in the cast pipeis assured.

I-t will also be apparent that the apparatus herein disclosed can be employed to determine the most desirable core bar types and also the changes inl the deilectional properties of core bars as the result of long use, exposure to high temperatures, or other abnormal conditions. By thus using the apparatus to detect an improper type of core bar,l losses which would ultimately result from the use of such improper types of core bars can be entirely eliminated. Thus, by designing or selecting core bars which will test well and control well, better casting practice will result, also when the life of core bars has been spent, the herein disclosed detecting and indicating gauge equipment Will` make known the deficiency of the core bars so that their use can be discontinued.

It is of course to be understood that the de;

tails of structure and the arrangement of parts may be variously changed and modied without departing from the spirit and scope of the in vention.

I claim:

l. In pipe casting apparatus, a flask structure, means for supporti-ng a hollow core in said flask structure in position for internally shaping pipe castings, said core being open at at least one end, a gauge lever eng-aged at one end internally in said core at a point intermediate the ends thereof and extending at its other end through and beyond the open end of the core, and means for indicating the degree of movement of said extended end of the lever to in turn indicate the degree of deflection of said core intermediate its ends.

2. In horizontal pipe casting apparatus, a horizontal flask structure, means for supporting a hollow core horizontally in said flask structure in position for internally shaping pipe castings and including devices adjustably engageable with said core for bending it so as to dispose the portion thereof intermediate its ends eccentrically in said flask structure, and means including an element engageable in the core intermediate its ends for detecting and. indicating changes in the degree of the eccentric positioning of said core intermediate portion which occur .during the pouring of the mold;

3. In horizontal pipe casting apparatus, a horizontal flask structure, means for supporting a hollow core horizontally in said flask structure in position for internally shaping pipe castings and including devices adjustably engageable with said core for bending it so as to dispose the portion thereof intermediate its ends eccentrically in said flask structure in anticipation of and for the purpose of compensating for deflection of said core intermediate portion by contact of the molten metal at the time the mold is poured, and means including an element engageable in the core intermediate its ends for detecting and indi.- cating the degree of deflection of said core intern mediate portion during the pouring of the mold.

4. In horizontal pipe casting apparatus, a horizontal flask structure, means for supporting a hollow core horizontally in said flask structure in position for internally shaping pipe castings and including devices adjustably engageable with said core for bending it so as to dispose the portion thereof intermediate its ends eccentrically in said flask ,structure in anticipation of and for the purpose of compensating for deilection of said core intermediate portion by contact of the molten metal at the time the mold is poured, and

means including an element engageable in thev core intermediate its ends for detecting and indicating the degree of deflection of said core intermedi'ate portion during the pouring of the mold, said devices being readjustable under Visual guidance of said detecting and indicating means for assuring perfect centering of said intermediate core portion in the ilask just prior to solidication of the metal of the cast.

5. In horizontal pipe casting apparatus, a horizontal flask structure, means for rsupporting a hollow core horizontally in said flask structure in position for internally shaping pipe castings and including devices adjustably engageable with said core for bending it so as to dispose the portion thereof intermediate its ends eccentrically in said flask structure, said core being open at at least one end and said detecting and indicating means including a gauge lever engaged at one end internally in said core at a point intermediate the ends thereof and extending at its other end through and beyond the open end of the core, and means for indicating the degree of movement of said extended end of the lever to in turn indicate the degree of deflection of said core intermediate its ends.

6. In horizontal pipe casting apparatus, a horizontal flask structure, means for supporting a hollow core horizontally in said flask structure in position for internally shaping pipe castings and including devices adjustably engageable with said core for bending it so as to dispose the portion thereof intermediate its ends eccentrically in said ilask structure in anticipation of and for the purpose of compensating for deflection of said core intermediate portion by contact of the molten metal at the time the mold is poured, and means for detecting and indicating the degree of deflection of said core intermediate portion during the pouring of the mold, said devices being readjustable under Visual guidance of said detecting and indicating means for assuring perfect centering of said intermediate core portion in the flask just prior to solidilcation of the metal of the cast, said core being open at at least one end and said detecting and indicating means including a gauge lever engaged at one end internally in said core at a point intermediate the ends thereof and extending at its other end through and beyond the open end of the core, and meansl for indicating the degree of movement of said extended end of the lever to in turn indicate the degree of deflection of said core intermediate its ends.

7. In horizontal pipe casting apparatus, a horizontal flask structure, means for supporting a hollow core horizontally in said flask structure in position for internally shaping pipe castings and including devices adjustably engageable with said core for bending it s0, as to dispose the portion thereofr intermediate its ends eccentrically in said flask structure, said core being open at at least one end and said detecting and indicating means including a gauge lever having a contact spider at one end thereof and said one end extended into the core so that said spider engages in the core intermediate the ends thereof and having its other end extended out through and beyond the open end of the core, a fulcrum rest for said lever disposed intermediately of the open end of the core and the outer end extremity of the lever, and gauge means engaging' said lever at an outer end portion thereof beyond said fulcrum rest and effective to indicate the degree of vertical and lateral movement imparted to the outer end of said lever by reason of the contact of said lever in the core intermediate the ends thereof and deflection of said intermediate core portion. p

8. In horizontal pipe casting apparatus, a horizontal flask structure, means for supporting a hollow'core horizontally in said iiask structure in position for internally shaping pipe castings and including devices adjustably engageable with said core for bending it so as to dispose the portion thereof intermediate its ends eccentrically in said flask structure, said core being open at at least one end and said detecting and indieating means including a gauge lever having a contact spider at one end thereof and said one end extended into the core so that said spider Aengages in the core intermediate the ends thereof vand having its other end extended out through and beyond the open end of the core, a fulcrum rest for said lever disposed intermediately of the open endof the core and the outer vend extremity of the lever, and a pair of gauges each having a springprojected actuator plunger engageable with an outer end portion of the lever beyond said fulcrum rest one said plunger being disposed uprightly for indicating the degree ofr vertical movement imparted to the outer end of the lesaid core for bending it so as to dispose the( portion thereof intermediate its ends eccentrical- 1y in said fiask struture, said core being open at at least one end and said detecting and indicating means including a gauge lever havin-g a by side in said flask in position for internally shaping pipe castings,said means inclutng cleyices adjustably engageable with each said core for bending it s0 as to dispose the portion thereof intermediate its ends eccentrically in said flask structure in anticipation of and for the purpose of compensating for deflection of said core intermediate portion by contact of the molten metal at the time the mold is poured, and means for detecting and indicating the degree ofr deflection of all said core intermediate portions during the pouring of the mold, said devices being readjustable under visual guidance of said detecting and indicating means for assuring perfect centering of each said intermediate core portion in the flask just prior to solidiflcation of the metal of the cast, each said core being open at at least one end and said detecting and indicating means including a gauge lever associated with each core and having a contact spider at one end thereof and said one end extended into the particular core so that saidspider'en-gages in the core intermediate the ends thereof and having its other contact spider at one end thereof and said one I V end extended into the core so that said spider engages in the core intermediate the ends thereof and having its other end extended out through and beyondthe open end of the core, a fulcrum rest for said lever disposed intermediately of the open end of the coreand the outer end extremity of the lever, a pair of gauges each having a spring projected actuator plunger engageable with an outer end portion of the lever beyond said fulcrum rest one said plunger being disposed'up- I rightly for indicating the degree of vertical movement imparted to the outer end of the lever by reason of the contact of said lever in the core intermediate the ends thereof and deflection of said intermediate core portion and the other of said plungers being disposed horizontally for in similar manner and by like reason indicating lateral movement of said lever outer. end portion, a single bracket supporting both gauges, and

means tiltably mounting the gauges on said bracket.

10. In horizontal pipe casting apparatus, a horizontal flask structure, means for supporting a plurality of hollow cores horizontally and side end extended out through and beyond the open end of the core, a fulcrum rest common to all said levers and disposed intermediately of the open ends of the cores and the outer end extremities of the levers, and gauge means engaging each lever at an outer end portion thereof beyond said fulcrum rest and effective to indicate the degree of vertical and lateral movement imparted to the outer end of the respective lever by reason of the contact of said lever in the core intermediate the ends thereof and deflection of the particular intermediate core portion.

11. Apparatus asdened in claim 10 in which each gauge means comprises a `pair of gauge units, each unit having a spring projected actuator plunger engageable with an outer end portion of the respective lever beyond the common fulcrum rest, one said plunger being disposed uprightly for indicating the degree of vertical movement imparted to the outer end of the engaged lever by reason of the contact .of said lever in j the respective core intermediate the ends thereeach gauge means comprises a pair of gauge.

units, each unit having a spring' projected actuator plunger engageable with an outer end portion of the respective lever beyond the common kfulcrum rest, one said plunger being disposed uprightly lfor indicating the degree of vertical movement imparted to the outer end of the engagedY lever by reason of the contact of said lever vin the respective core intermediate the ends thereof and deflection of said intermediate core portion and the other of said plungers being disposed horizontally for in similar manner and by like reason indicating lateral movement of said lever outer end portion, a support beam disposed ltransversely With respect to the outer ends of all of the levers, a single bracket verticallyadjustably mounted on the support beam adjacent the outer end of each lever, and means tiltably mounting'each gauge unit of each unit pair on one of said brackets.

' JOHN ELIJAI-I GOATES. 

